Series 6495 TROVIS 6495-2 Industrial Controller For panel mounting (front frame 96 x 96 mm/3.78 x 3.78 inch) Application Digital controller to automate industrial and process plants for general and more complex control tasks Suitable for control of continuous, on/off or pulsing final control elements (pneumatic actuators with i/p positioners, electric actuators, electric heating systems, refrigerating machines etc.) The TROVIS 6495-2 Industrial Controller has two independent internal controllers with common input and output sections. By setting the configuration items and, the controller can be adapted to a control task quickly. Preset basic configurations for each control type minimize setup work for standard applications. The controller can be set up directly at the controller or using the optional TROVIS-VIEW software. The controller settings are saved in a non-volatile memory, even when the power supply fails. The two internal controllers can be operated directly without switching over. The plain-text display (German, English, French) facilitates configuration and parameterization. Special features Simple menu structure with plain text readings Four analog inputs with filtering, root extraction and function generation as well as measuring range monitoring Four digital inputs for set point switchover, constant output value, reversal of operating action, output tracking (DDC backup), ramps etc. Three analog outputs Four relay outputs for two on-off/three-step outputs or limit alarms Two transistor outputs for status alarms One transistor output for fault alarms Optional RS-232/USB and RS-485 Modbus RTU/USB interface boards for SSP and Modbus RTU Degree of protection (front) IP 65 Plug-on screw terminals Fixed set point control, one or two channels, internal/external switchover Follow-up control, one or two channels, internal/external switchover Ratio control Cascade control, consisting of master and slave controller Override control Mixing control inking of input variables (addition, subtraction, multiplication, division, mean value, minimum and maximum selection) for feedforward control or control with max. four input variables (multi-component control) Electronics from SAMSON Fig. 1 TROVIS 6495-2 Industrial Controller Operation with max. four internal set points and one external set point, either analog or over interface (SPC mode) Set point ramp and output ramp Split-range operation Control mode switchover P/PI or PD/PID KP or TN adapted using the controlled variable, reference variable, manipulated variable or error Adjustable limitation of integral-action component Operating point determined by set point or digital input Control signal limitation (fixed or floating according to input variable) Operation with key number or key locking over the digital input Edition July 2015 Data Sheet T 6495-2 EN
Inputs and outputs (Fig. 3) Four analog inputs (AI 1 to AI 4) DIP switches at the side of the case are used to initially select current or resistance inputs. The signal type is set depending on the configuration: 0 (4) to 20 ma, 0 (2) to 10 V, Pt 100, Pt 1000; input 2 additionally for potentiometer. Four digital inputs (DI 1 to DI 4) The digital inputs are controlled either by a 24 V DC voltage signal or by the transmitter supply using a floating contact. The digital outputs can only be controlled in groups, with DI 1 and DI 2 being the first group, and DI 3 and DI 4 being the second group. Example: internal supply for digital inputs DI 1 and DI 2, and external supply for digital inputs DI 3 and DI 4. Three analog outputs (AO1 to AO3) The signal type is set depending on the configuration: 0 (4) to 20 ma, 0 (2) to 10 V. Outputs AO1 and AO3 can optionally be used for other signals as well. Seven digital outputs Four relay and three transistor outputs The relay outputs can be used to implement on/off, three-step (SO1 and SO2) or limit outputs (DO 1 to DO 4). The transistor outputs DO 5 and DO 6 can be used to issue status alarms; fault alarms can be issued at transistor output DO 7. Power supply The controller comes with two different power supply units. Specify the required version in your order: 85 to 264 V AC 24 V AC/DC Supply output (auxiliary voltage) A maximum of four two-wire transmitters and four digital inputs can be supplied by this output (21 V DC, 90 ma). Infrared interface (Fig. 2) Data are transmitted between the controller and the TROVIS-VIEW Configuration and Operator Interface over an infrared interface integrated into the controller and an infrared adapter (order no. 8864-0900) connected to a PC. 2 1 0.7 m 25 Fig. 2 Connecting an infrared adapter 1 Infrared adapter 2 Port of the computer (COM or with USB 1.1 serial adapter at the USB port) Communications interface The controller can optionally be fitted with one of the two following interface boards. The boards can be retrofitted. RS-232/USB interface board with RS-232 interface (RJ 12 connector) and USB interface (5-pin mini-b connector) RS-232 data transmission uses SSP or Modbus RTU protocol. RS-485/USB interface board with RS-485 interface (four terminals) and USB interface (5-pin mini-b connector) RS-485 data transmission uses SSP or Modbus RTU protocol. The two-/four-wire operation and the active bus termination can be set over slide switches. TROVIS 6495-2 Analog- inputs ma, V, Pt 100, Pt 1000 ma, V, Pt 100, Pt 1000, potentiometer ma, V, Pt 100, Pt 1000 AI1 AI2 AI3 AO1 ma,v AO2 ma,v AO3 ma,v Analog- outputs ma, V, Pt 100, Pt 1000 Digital- inputs AI4 DI1 DI2 DI3 DI4 1 2 DO1 DO2 DO3 DO4 ON/OFF Digital outputs (relay) imit alarms PWM 3-step 3-step PWM On/off or three-step switching output SO1 On/off or three-step switching output SO2 Inter- faces IR Interface DO5 DO6 Digital outputs (transistor) Status alarms DO7 Fault alarms Supply voltage Supply output for transmitter Fig. 3 Overview of inputs and outputs 2 T 6495-2 EN
Operation Display and operating controls (Figs. 4) The device has nine operator keys, of which three are assigned to each controller. Depending on the selected control mode, one or two controllers are activated. Controller [1] is displayed and operated on the left, Controller [2] on the right, or optionally vice versa. The row of keys in the middle is used for both controllers. Operating level After the power supply has been switched on, the controller is in the operating level. The readings of the controlled variable, the reference variable and the manipulated variable for each controller as well as a bar graph for error are indicated on the display (1). Depending on the configuration, status alarms of the digital inputs and outputs can be shown. The operating menu allows set points to be switched and control to be changed. The two rows at the bottom of the display can be assigned as desired. The user can choose between various signals and intermediate calculations inside the controller. For example, the values or a bar graph of two outputs in split-range operation can be displayed. Configuration and parameterization In the configuration level, the controller is adapted to the control task to be completed. The functions are arranged in hierarchical menus. All settings are displayed as plain text. 9 1 1.1 1.2 3.1 3.2 8 2 4.2 4.1 7 5.1 6 5.2 1 Display 1.1/1.2 Bar graph for error, controller [1]/[2] 2 Infrared interface 3.1/3.2 Manual/automatic key, controller [1]/[2] 4.1/4.2 Cursor key, controller [1]/[2] 5.1/5.2 Cursor key, controller [1]/[2] 6 Escape key 7 Enter key 8 Info key 9 abel area Fig. 4 Display and operating controls Key Manual/ automatic key Cursor keys Enter key Info key Key functions in the levels Operating level Info menu Operating menu Configuration level Switch between manual and automatic control mode Cascade control: Open/close controller cascade Automatic mode: Change set point Manual mode: Change output value Enter main menu (operating menu and configuration level) No function No function Edit individual items of Browse through menu and information Browse through a menu Change set point and control Enter menu Confirm settings Switch over set point Open info menu No function No function No function Browse through menu, submenu, configuration items and Change configuration items and Enter menu and submenu, activate configuration items and Confirm setttings Escape key Confirm restart after power supply failure Return to the operating level step by step Return to the operating level step by step Return to the operating level step by step 3 T 6495-2 EN
Operation using TROVIS-VIEW Controller settings (Fig. 5) Configuration settings and can conveniently be adjusted, documented and transmitted using the optional TROVIS-VIEW software. Working in TROVIS-VIEW is similar to working in Windows Explorer. TROVIS-VIEW includes a trend viewer for start-up that records the process data. Input and output variables are displayed in a clear structure. The TROVIS-VIEW software is delivered on a CD-ROM. For further information on TROVIS-VIEW refer to Data Sheet T 6661 EN. Data transmission (Fig. 6) See section on accessories on page 8 for order numbers. Data can be transmitted between TROVIS-VIEW and the controller in different ways: Data transmission using the infrared interface (11) and an infrared adapter (14) Data transmission using the optional interface board with RS-232 and USB connections: data can be transmitted over a conventional cable, either a USB cable (13) or a connecting cable (15), and a memory pen (16). The controller can be fitted with the optional RS-485 interface board to integrate it into a communications network. This interface board has a USB port used to transmit data over TROVIS-VIEW. Fig. 5 Operation using TROVIS-VIEW 10 16 17 18 TROVIS 6495-2 11 15 19 12 14 10 RJ-12 connector socket 11 Infrared interface 12 USB interface 13 USB cable (mini-b, 5-pin USB type A) 14 Infrared adapter (RS-232) 15 Connecting cable RJ 12/D-sub 9-pin (RS-232) 16 Memory pen (RS-232) 17 Modular adapter RJ 12/D-sub 9-pin (RS-232) 18 COM port (RS-232) on the computer 19 USB port on the computer Fig. 6 Data transmission 13 USB 1.1 serial adapter It can be connected under Windows 2000 or Windows XP either over the COM port of the computer or over the USB 1.1 serial adapter. 4 T 6495-2 EN
Technical data TROVIS 6495-2 Inputs 4 analog inputs ma, V, Pt 100, Pt 1000, input 2 also for potentiometer ma or V inputs Resistance thermometer Version Nominal signal range Resolution Permissible signal range Input resistance Static destruction limit Differential input 0 to 20 ma, 4 to 20 ma, 0 to 10 V, 2 to 10 V < 0.007 %, based on nominal signal range 1 to 22 ma or 0.5 to 11 V 50 Ω with current; 10 kω with voltage ±50 ma for current input ±30 V for voltage input For sensor Pt 100, Pt 1000, according to DIN EN 60751 Nominal signal range Connection Resolution 50 to 300 C (58 to 572 F) Potentiometer Nominal values 100, 200, 500, 1000 Ω General specifications 4 digital inputs Connection Resolution < 0.006 % Measuring error of inputs Three-wire circuit (resistance per lead < 15 Ω), two-wire circuit < 0.02 K (0.006 % based on nominal signal range) Three-wire circuit, resistance per lead < 15 Ω < ± 0.2 % of nominal signal range for zero, span, linearity Ambient temperature influence < ± 0.1 %/10 K for zero and span, based on 20 C Input filter Function generation Signal increase/drop User calibration Adjustable Adjustable using 7 points Adjustable Adjustable Transmitter fault alarm Adjustable, input signal < 5 % or > 105 % Transmitter supply Control Supply output, terminals 89 and 90, 21 V DC, max. 90 ma, resistant to short-circuiting Switching contact with external supply 24 V DC (17 to 31 V DC) or supplied by the controller over terminals 89 and 90 (21 V DC) Signal state 'OFF' at 0 to 10 V, signal state 'ON' at 17 to 31 V, signal inversion can be configured Current consumption 3.1 ma at 24 V DC and 2.4 ma at 21 V DC DI1 and DI2 as well as DI3 and DI4 are galvanically connected on one side Outputs 3 analog outputs 7 digital outputs Relay outputs Transistor outputs Interfaces Infrared interface Nominal signal range 0 to 20 ma, 4 to 20 ma, 0 to 10 V, 2 to 10 V Max. permissible signal range 0 (2.4) to 22 ma or 0 (1.2) to 11 V oad < 750 Ω for current; > 3 kω for voltage Error of outputs < ± 0.2 % of the nominal signal range for zero, span, linearity Ambient temperature influence < ± 0.1 %/10 K for zero and span, based on 20 C Resolution < 0.03 %, based on nominal signal range Static destruction limit ±30 V 4 relays with floating NO contact, can be inverted Permissible contact load 264 V AC, 1 A AC, cos φ = 1 or 250 V DC, 0.1 A DC Spark suppression Parallel connection C = 2.2 nf and varistor 300 V AC, in parallel to each relay contact 3 electrically isolated transistor outputs External supply 3 to 42 V DC, max. 30 ma Transmission protocol SAMSON-specific protocol (SSP) Data that can be transmitted Controller settings, process variables, operating status Transmission rate 9600 bit/s Angle of deflection 50 Distance IR adapter controller 70 cm 5 T 6495-2 EN
Technical data (continued) RS-232/USB (accessories) RS-485/USB (accessories) General specifications Power supply Power consumption RS-232 with electrical isolation, USB (slave) Connection USB: 5-pin mini-b RS-232: RJ 12 Transmission protocol Data that can be transmitted RS-485 with electrical isolation, USB (slave) Connection Transmission protocol Data that can be transmitted Transmission rate/ format USB: SAMSON-specific protocol (SSP) RS-232: SSP and Modbus RTU Controller settings, process variables, operating status, fault alarms USB: 5-pin mini-b RS-485: 4-pin screw terminals USB: SAMSON-specific protocol (SSP) RS-485: SSP and Modbus RTU Controller settings, process variables, operating status, fault alarms SSP: 9600 bit/s, 8 bit, no partity bit, 1 start bit Modbus: 300 to 115200 bit/s, 8 bit, parity bit adjustable, 1 (2) stop bits Type of transmission RS-485: Asynchronous, half duplex, 4-wire or 2-wire Number of connected devices Number of addressable stations Modbus: 246 ine length Bus termination Transmission medium RS-485: 32 (can be extended when a repeater is used) RS-485: < 1200 m, max. 4800 m with repeater RS-485: Active, selectable RS-485: 2 or 4 cores (twisted-pair cabling, stranded in pairs, with static shield) 85 to 264 V AC, 47 to 63 Hz or 24 V AC/DC (20 to 30 V), 47 to 63 Hz 85 to 264 V AC: max. 19 VA, external fuse > 630 ma (slow) 20 to 30 V AC/DC: max. 15 VA, external fuse > 1.25 A (slow) Temperature Ambient: 0 to 50 C Storage: 20 to 70 C Relative humidity Degree of protection (EN 60529) Max. 95 %, non-condensing IP 65 (front), IP 30 (housing), IP 00 (terminals) Device safety (EN 61010-1) Class of protection II Overvoltage category II Degree of contamination 2 Electromagnetic compatibility Requirements according to EN 61000-6-2, EN 61000-6-3 and EN 61326-1 Environmental effects for storage, transportation and operation Electrical connection Display Display range Cycle time Configuration Control types Weight Compliance Dimensions in mm (inch) Sinusoidal vibrations acc. to IEC 60068-2-6 Random vibrations acc. to IEC 60068-2-64 Shocks acc. to IEC 60068-2-27 2 to 9 Hz / amplitude 3.5 mm 9 to 200 Hz / acceleration 10 m/s² 200 to 500 Hz / acceleration 15 m/s² 1.0 m²/s³; 10 to 200 Hz 0.3 m²/s³; 200 to 2000 Hz Acceleration 100 m/s², duration 11 ms Plug-on screw terminals 1.5 mm² (cross-section of the line 0.5 to 1.5 mm²) Dot matrix display with 132 x 49 pixels 999 to 9999; start value, end value and decimal separator can be adjusted 50 ms Functions saved in read-only memory, configuration saved in non-volatile memory One or two fixed set point/follow-up control, one ratio control, one cascade control, one ratio and fixed set point/follow-up control, one limitation control 0.5 kg Mounting clips Terminal strips 1 2 3 4 Panel cut-out and minimum distances when installing several TROVIS 6495-2 Controllers 96 (3.78") 91.2 (3.59") Panel cut-out 92 0.8 (3.62" 0.3 ) >30 92 0.8 (3.62" 0.3 ) 96 (3.78") 150 (5.90") 156 (6.14") Slot for interface board >15 6 T 6495-2 EN
Electrical connection Terminal strip 1 Current Current 2-wire transmitter Voltage Resistance thermometer Potentiometer 0/4 to 20 ma 4 to 20 ma 0/2 to 10 V Pt 100/Pt 1000 3-wire 2-wire 100/200/500/1000 Ω 3-wire 2-wire Supply out* 21 V DC max. 90 ma Input AI1 89 90 11 12 13 Input AI2 15 16 17 0 % 100 % 0 % 100 % Input AI3 19 20 21 Input AI4 23 24 25 Terminal strip 2 Current 0/4 to 20 ma Voltage 0/2 to 10 V Digital input with internal supply Digital input with external supply Supply output 21 V DC, max. 90 ma 89 90 31 Analog output AO1 32 33 Digital input DI1 GND Digital input DI2 81 82 83 24 V DC 35 Analog output AO2 36 37 97 Analog output AO3 98 Digital input DI3 GND Digital input DI4 99 85 86 87 24 V DC 7 T 6495-2 EN
Electrical connection (continued) Terminal strip 3 Digital output DO5 Digital output DO6 Digital output DO7 61 62 63 64 65 66 Supply 3 to 42 V DC, max. 30 ma Terminal strip 4 Supply voltage N () 85 to 264 V AC 24 V AC/DC (20 to 30 V) N N () Three-step output for motor-driven actuator On/off output with pulse-position modulation Digital output: limit values, alarms, on/off output Switch output SO1 () Digital output DO1 Switch output SO1 () Digital output DO2 42 43 52 53 N Switch output SO2 () Digital output DO3 Switch output SO2 () Digital output DO4 45 46 55 56 N Electrical isolation Article code Industrial controller TROVIS 6495-2 x Analog inputs Analog outputs Power supply 85 to 264 V AC 24 V AC/DC 1 2 Digital inputs Internal supply Digital outputs (relay) for three-step, on/off, limit alarms Accessories Order no. Digital inputs External supply Interface Digital outputs (transistor) for fault and status alarms Transmitter supply TROVIS-VIEW Operator Interface... 6661-1033 Infrared adapter (RS-232)... 8864-0900 Bracket for infrared adapter... 1400-9769 USB 1.1 serial adapter... 8812-2001 Supply voltage Electrical isolation Interface board RS-232/USB... 1400-9917 Interface board RS-485/USB... 1400-9918 USB cable (2 m) with type A and 5-pin mini-b connectors... 8801-7301 Cable RJ 12/D-sub 9-pin (RS-232)... 1400-7699 Memory pen (RS-232)... 1400-9753 Modular adapter RJ 12/D-sub 9-pin... 1400-7698 Specifications subject to change without notice SAMSON AG MESS- UND REGETECHNIK Weismüllerstraße 3 60314 Frankfurt am Main Germany Phone: 49 69 4009-0 Fax: 49 69 4009-1507 Internet: http://www.samson.de : T 6495-2 EN 2015-12